Screen basket and shale shakers

ABSTRACT

A screen mounting basket for a vibratory separator for separating components of material introduced into the basket, the vibratory separator including a collection receptacle beneath the basket, the basket including two opposed spaced-apart side walls having first ends and second ends, the first ends spaced-apart by spaced-apart end walls connected to each of the side walls, a basket bottom between the two spaced-apart side walls, at least one screen assembly positioned vertically in the basket for interceptions material introduced into the basket and for screening said material, and the at least one screen assembly extending from one side wall of the basket to the other.

RELATED APPLICATION

This is a continuation-in-part of U.S. Ser. No. 10/169,484 filed Sep.16, 2002 (issued as U.S. Pat. No. 6,863,183 on Mar. 8, 2005) which is adivision of U.S. application Ser. No. 09/716,176 filed Nov. 17, 2000,issued as U.S. Pat. No. 6,371,301 B1 on Apr. 16, 2002; and thisapplication claims priority from PCT Application No. PCT/GB01/04667,Int'l Publication No. WO 02/40186 A1, filed Oct. 19, 2001, all of whichare incorporated fully herein for all purposes and from all of which thepresent invention claims priority under the Patent Laws.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to vibratory separators,screen-supporting baskets for them, and, in certain particularembodiments, to shale shakers for treating drilling fluid,screen-supporting baskets for them, screens for such separators andshakers and methods of using such screens, shakers, baskets, andseparators.

2. Description of Related Art

Vibratory separators are used in a wide variety of industries toseparate materials such as liquids from solids or solids from solids.Typically such separators have a basket mounted in or over a receivingreceptacle and vibrating apparatus for vibrating the basket. One or morescreens is mounted in the basket. Material to be treated is introducedto the screen(s). Separated material (e.g. liquid and/or smaller solids)flows through the screen(s) into the lower receptacle and separatedlarger solids (with or without liquid) move down and off the screen(s).

The need for solids control in drilling fluid or “mud” used inhydrocarbon well drilling is well known in the prior art. Drilling mud,typically a mixture of clay and water and various additives, is pumpeddown through a hollow drill string (pipe, drill collar, bit, etc.) intoa well being drilled and exits through holes in a drillbit. The mudpicks up cuttings (rock) and other solids from the well and carries themupwardly away from the bit and out of the well in a space between thewell walls and the drill string. At the top of the well, thesolids-laden mud is discharged over a shale shaker, a device whichtypically has one or a series of screens arranged in tiered or flatdisposition with respect to each other. The prior art discloses a widevariety of vibrating screens, devices which use them, shale shakers, andscreens for shale shakers. The screens catch and remove solids from themud as the mud passes through them. If drilled solids are not removedfrom the mud used during the drilling operation, recirculation of thedrilled solids can create weight, viscosity, and gel problems in themud, as well as increasing wear on mud pumps and other mechanicalequipment used for drilling.

Typically, the screens used with shale shakers are emplaced in agenerally horizontal fashion on a generally horizontal bed or supportwithin a basket in the shaker. The screens themselves may be flat ornearly flat (i.e. substantially two-dimensional); or, due to corrugated,depressed, or raised surfaces, are three-dimensional. The shaker impartsa rapidly reciprocating motion to the screen. Material from whichparticles are to be separated is poured onto a back end of the vibratingscreen. The material generally flows toward the front end of the screen.Large particles are unable to move through the screen, remain on top ofthe screen, and move toward the front of the screen where they arecollected. The smaller particles and fluid flow through the screen andcollect in a bed, receptacle, or pan beneath the screen.

Referring now to FIG. 1, a prior art shale shaker 1 has a screen 2 (withscreen or screening cloth or mesh as desired) mounted on vibratablescreen mounting apparatus or “basket” 3. The screen 2 may be any knownscreen or screens. The basket 3 is mounted on springs 4 (only two shown;two as shown are on the opposite side) which are supported from a frame6. The basket 3 is vibrated by a motor 5 and interconnected vibratingapparatus 8 which is mounted on the basket 3 for vibrating the basketand the screens. Elevator apparatus 7 provides for raising and loweringof the basket end. Typically the basket will be in a “climb the hill”position (see FIG. 4) so that a pool 9 of liquid is maintained at oneend within the basket.

FIG. 2 discloses one example of a typical prior art shaker system (e.g.as shown in U.S. Pat. No. 5,190,645). The system A has a shale shaker Khaving a screen or screens S. The screen(s) S are mounted in a typicalshaker basket B and one or more vibrators V (any known suitable shakervibrator) vibrate the basket B and hence the screen(s) S. The othercomponents of the system A are as described in U.S. Pat. No. 5,190,645incorporated fully herein for all purposes.

FIG. 3 shows schematically a prior art system C with a Mud Box (Backtank, Possum Belly) to distribute the flow to a screening surface. Thescreens are mounted in a Deck (Basket) which is vibrated to assist thethroughput of mud and movement of separated solids. The deck rests onVibration Isolation Members, such as helical springs or rubber mounts.The vibration isolation members rest on the support member, which isalso used to divert flow as desired, and is called a Bed. There are manydeck, basket configurations used depending on the design criteria. Thedeck, basket, may be flat, horizontal, or mounted at a slope.

On sloped deck units (e.g. cascade or parallel flow), the screens may becontinuous with one screen covering the entire deck length, or have adivided deck which has more than one screen used to cover the screeningsurface, or with individual screens mounted at different slopes. Onmultiple deck units, more than one screen layer may be employed. In atwo or three deck unit, the mud passes through one screen before flowingthrough the second.

The motion of the shaker controls the efficiency of separation, rate oftravel of cuttings on the screen, solids separation capacity and fluidcapacity. The shape and axial direction of the vibration motion alongthe deck is controlled by the position of the vibrator relative to thedeck and the direction of rotation of the vibrator.

Shale shakers have capacity limits. Exceeding a capacity limit meansexcessive mud will be discharged over the ends along with the solids.Capacity limits are typically defined for non-blinded screens. Capacitylimits of a shale shaker include:

-   -   1. The solids capacity limit is the maximum amount of solids        that a device will remove; and    -   2. The liquid limit—the maximum GPM capacity for various        drilling muds.

The solids capacity limit is encountered when drilling soft, gummyformations. Usually the liquid limit controls the minimum size screenthat can be used for a given circulation rate. The thicker the mud, thelower the GPM capacity. Open area of the screens and usable area of thescreening deck influence this limit. The solids capacity and/or liquidcapacity varies with different shaker designs. In practice, the smallestscreen size that can be employed without flooding a unit is used.

There is a need for an efficient vibratory separator system which isefficient and cost-effective with increased efficiency, and screenthroughput.

SUMMARY OF THE PRESENT INVENTION

The present invention discloses, in at least some aspects, a screenmounting basket for a vibratory separator or shale shaker for separatingcomponents of material introduced into the basket (e.g. drillingcuttings material), the vibratory separator including a collectionreceptacle beneath the basket, the basket including two opposedspaced-apart side walls having first ends and second ends, the firstends spaced-apart by spaced-apart end walls connected to each of theside walls; a basket bottom between the two spaced-apart side walls; atleast one screen assembly positioned vertically in the basket forintercepting material introduced into the basket and for screening saidmaterial; and the at least one screen assembly extending from one sidewall of the basket to the other. The present invention discloses, in atleast certain aspects, a screen-supporting basket for a shale shaker orother vibratory separator that includes two side walls spaced-apart andinterconnected by an end wall at a first end. A second end has bracing,bars, or beams spacing-apart the side walls, the bracing etc. positionedso that an end of a screen is above it. One or more screens (any knownin the art) for treating fluid introduced at the shaker's first end aremounted int he basket in any way known in the art. The basket is mountedover a receptacle for receiving fluid and/or solids flowing through thescreen(s).

The end wall at the first end of the basket has an opening therethrough.An upright end screen is emplaced over or in this opening so that liquidand/or solids in the material introduced into the basket may flowthrough this screen and into the receptacle below the basket. Such anend screen according to the present invention can be provided for anyknown basket when an end opening according to the present invention isprovided in the basket's end wall. Such an end opening may be anydesired size or shape and can extend for only a portion or oversubstantially all of the end wall.

In one aspect the screen is releasably held in place over the end-wallopening by sliding it down into channel members on either side of theopenings and blocking or wedging it in place. Any suitable seal orgasket or sealing material may be used on the screen, on the channelsand opening edge, or on both to sealingly position the screen over theopening. Any other suitable method or structure may be used toreleasably position and hold the end screen over the end opening,including, but not limited to, channels alone, nuts and bolts, clamps,glue or other adhesive, releasably cooperating fastener material such asVELCRO™ material, or screws. Any known inflatable structure or bladder,or releasable tensioning bolts may be used to hold a screen in place.Alternatively the screen can be welded, soldered, or brazed at theopenings edges. The end screen may be a single integral screen ormultiple adjacent end-to-end screens may be used at the basket end.Also, multiple adjacent vertical screens may be used positioned so thatfluid from within the basket flows through all of them. Such vertically“stacked” screens may all be mounted within the basket; outside thebasket; or one or more of them may be mounted within the basket and oneor more of them mounted outside the basket—with appropriate mountingmembers, gaskets, seals, seal members, and/or bolts and nuts so thatfluid flows through the screens and then exits from an outermost screen.

In one aspect the end screen has a plate, mounting structure, or frameand with a lower part that is perforated or has holes or openings sothat fluid flowing onto it flows through this part of the frame and outand down into the collection receptacle beneath the basket.

A shaker, in one embodiment according to the present invention, e.g.with basic components as the shaker in FIG. 1, is, according to thepresent invention, provided with a basket as described herein accordingto the present invention.

In other aspects one or both sides of a basket as described aboveaccording to the present invention also has one or more side screensthrough which fluid and/or solids from the material introduced into thebasket can flow out and down into the collection below the basket.Optionally, there is no end screen as described above and only screen(s)on one or both side walls. Such side wall screens may be any asdescribed above mounted in any way as described above for end screens.

In one basket according to the present invention a plurality of openingsare provided on the side walls and end walls of the basket and, asdesired, a screen may be used over any, some, or all the openings. Foran opening not covered by a screen, a blocking plate or member isreleasably and sealingly installed over the opening(s) to close off theopening to flow. According to the present invention one or more suchscreens may be installed within the basket on its interior over theopening or on the basket's exterior surface over the opening.Alternatively, with appropriate holding devices, a screen according tothe present invention may be sized to fit sealingly within an opening.Any known flat, substantially flat, two-dimensional or three-dimensionalscreen or screen assembly, appropriately sized and configured, may beused according to the present invention to close off one or more endand/or side basket openings.

A basket as described above according to the present invention providesmore screening area to treat material and separate its components than aconventional basket with the same footprint. By thus increasing theavailable screening area, the load on the horizontal screen(s) isreduced; their efficiency, and productivity are increased; and totalthroughput for the basket is increased. Shaker or screen capacity istypically determined by the position of a “fluid-end point”. The fluidend-point is the point where the fluid pool stops on the screen surfacenear the shaker's discharge end. As the fluid-end point moves closer tothe discharge end, discharged solids can become too wet, risking wholemud losses over the screen. A typical rule of thumb for optimum shakercapacity specifies covering 66% or less of the shaker's screen surface.The integration of vertical screens into a shaker basket according tothe present invention shortens the length of the fluid pool, effectivelyincreasing shaker capacity.

Solid loading has as great an effect on shaker capacity as liquidvolume. As solids take up screen area, liquid throughput is impeded dueto the moving solids bed on the screen surface. The effect of heavysolids loading on screening capacity is exponential. Heavy solidsloading creates a condition for fluid to ride on top of the movingsolids bed, and creates conditions susceptible to whole mud losses. Onesolution to this problem has been to use coarser screens to preventwhole mud losses. This solution solves the immediate concern for theloss of whole mud, but may be at the expense of poor solids control.

The motion of the basket conveys solids away from the vertical screen(s)at the rear and/or sides of the shaker basket. Thus some portion of thefluid in the pool that exits through end and/or side basket screen(s)according to the present invention bypasses the traditional routing ofprior art baskets, thereby enhancing shaker capacity.

Baskets according to the present invention with one or more screensaccording to the present invention enhance capacity, especially if thereis enough flow to generate a pool on the screen surface. This isparticularly true during heavy solids loading due to high penetrationrates and large diameter hole conditions, or both.

In certain aspects, the end screen in a basket according to the presentinvention is at such an angle to the direction of the force of strokesof the vibrating apparatus that separation is enhanced as compared tothe angle of these strokes with respect to the horizontal screen(s).

When a basket in a shaker has one elevated end (as shown in FIG. 4) sothat the separated solids run “uphill”, liquid is prevented from runningoff the screen's exit end; and a pool of liquid is formed at thebasket's opposite end—by using an end wall opening(s) and screen(s)and/or appropriately located side wall opening(s) and screen(s) aportion of this liquid (and perhaps some small separated solids) flowsout from the basket through the end screen(s) and/or side screen(s) andthe horizontal screen(s) in the basket beyond the pool are not impactedby and do not have to process this portion of the liquid that flows outthrough the end screen (s) and/or side screen(s). Optionally, part orall of a basket's floor may be closed off to flow rather than completelyor substantially completely covered with screen(s). In one aspect partof all of the area beneath a pool formed in a basket is closed off toflow and side and/or end screens treat the pool material.

The present invention, in one embodiment includes a shale shaker with aframe; a “basket” or screen mounting apparatus in the frame; one or morescreens positioned in a flat position in the basket; basket vibratingapparatus; one or more end basket screens and/or one or more side basketscreens; and a collection tank or receptacle below the basket. In oneparticular aspect such a shale shaker treats drilling fluid.

In certain embodiments the present invention discloses a screen mountingbasket for a vibratory separator for separating components of materialintroduced into the basket, the vibratory separator including acollection receptacle beneath the basket, the basket with two opposedspaced-apart side walls having first ends and second ends, the firstends spaced-apart by an end wall connected to each of the side walls, abasket bottom opening between the two spaced-apart side walls, basketbottom screening apparatus at the basket bottom opening, at least onebasket aperture not through the basket bottom, at least one aperturescreen over the at least one basket aperture, and the at least oneaperture screen and the bottom screening apparatus for separating acomponent material from the material introduced into the basket,material flowing through the at least one aperture screen not flowingthrough the bottom screening apparatus, the separated component materialflowing into the collection receptacle.

The present invention discloses, in certain aspects a screen apparatusfor a vibratory separator, the vibratory separator having a basket, thevibratory separator for separating components of material introducedinto the basket, the vibratory separator including a collectionreceptacle beneath the basket, the screen apparatus including screeningmaterial, a support, the screening material on the support, the supporthaving a plurality of openings therethrough suitable for the flow offluid therethrough, the fluid from the material introduced into thebasket, the support having a plurality of fluid conducting channelstherein at an angle to the plurality of openings so that fluid flowinginto one of the plurality of openings may then flow into one of theplurality of fluid conducting channels and out from the support into thereceptacle. In one aspect a screen assembly with such a support (e.g. aframe or a plate) is stood on end at an end or side basket opening.

The present invention discloses, in certain aspects, a vibratoryseparator system for separating components from a liquid-solid mixturefed to the vibratory separator system, the vibratory separator systemwith a frame, a screen mounting basket on the frame, vibrating apparatusconnected to the screen mounting basket for vibrating the screenmounting basket, the screen mounting basket like any described hereinaccording to the present invention.

The present invention discloses, in certain aspects, a method forreducing the weight of material on the bottom screening apparatus of avibratory separator, the vibratory separator having a screen mountingbasket into which the material is introduced, the vibratory separatorincluding a collection receptacle beneath the basket, the basket with aplurality of interconnected walls, a basket bottom opening between thewalls, basket bottom screening apparatus at the basket bottom opening,at least one basket aperture through one of the walls and not throughthe basket bottom, at least one aperture screen over the at least onebasket aperture, and the at least one aperture screen and the bottomscreening apparatus for separating a component material from thematerial introduced into the basket, the separated component materialflowing into the collection receptacle, the method including introducingthe material into the basket, flowing part of the material through theat least one aperture screen, said part flowing into the receptaclewithout passing through the bottom screening apparatus.

It is, therefore, an object of at least certain preferred embodiments ofthe present invention to provide:

New, useful, unique, efficient, non-obvious baskets for vibratoryseparators and shale shakers and methods for using them to separatecomponents of material to be treated thereby.

Such baskets with one or more end wall openings with one or more endwall screens for treating material; and/or with one or more side wallopenings with one or more side wall screens for treating material;

Such a basket which provides for a pool on top of a topmost screeninglayer that has a pool end boundary that is relatively further away froma discharge end of a shaker as compared to such pools in prior artshakers or vibratory separators;

Such a shaker with any such basket; and

A system with any such basket that has relatively increased throughputand which increases screen life.

The present invention recognizes and addresses the previously-mentionedproblems and long-felt needs and provides a solution to those problemsand a satisfactory meeting of those needs in its various possibleembodiments and equivalents thereof. To one of skill in this art who hasthe benefits of this invention's realizations, teachings, disclosures,and suggestions, other purposes and advantages will be appreciated fromthe following description of preferred embodiments, given for thepurpose of disclosure, when taken in conjunction with the accompanyingdrawings. The detail in these descriptions is not intended to thwartthis patent's object to claim this invention no matter how others maylater disguise it by variations in form or additions of furtherimprovements.

U.S. application Ser. No. 09/716,176 filed Nov. 17, 2000 is incorporatedherein fully for all purposes.

DESCRIPTION OF THE DRAWINGS

A more particular description of embodiments of the invention brieflysummarized above may be had by references to the embodiments which areshown in the drawings which form a part of this specification. Thesedrawings illustrate certain preferred embodiments and are not to be usedto improperly limit the scope of the invention which may have otherequally effective or equivalent embodiments.

FIG. 1 is a perspective view of a prior art shale shaker.

FIG. 2 is a schematic view of a prior art shaker system.

FIG. 3 is a schematic view of a prior art shaker.

FIG. 4 is a side view of a basket for a shaker as shown in FIG. 1.

FIG. 5A is a side view of a basket according to the present invention.FIG. 5B is a perspective view of a screen for the basket of FIG. 5A.FIG. 5C is an end view and FIG. 5D is a partial top view of the basketof FIG. 5A. FIG. 5E is a side view of a basket according to the presentinvention. FIG. 5F is a perspective view of a screen assembly accordingto the present invention. FIG. 5G is a side view of a basket accordingto the present invention. FIG. 5H is a top schematic view of a basketaccording to the present invention with screens according to the presentinvention.

FIG. 6A is a perspective view of a plate according to the presentinvention for a screen according to the present invention. FIG. 6B is atop view of a perforated plate according to the present invention. FIG.6C is a cross-section view along line 6C-6C of FIG. 6B. FIG. 6D is a topview of a screen assembly according to the present invention.

FIGS. 7A-7F are perspective views of baskets according to the presentinvention.

FIG. 8 is a perspective view of a plate or sheet for a basket accordingto the present invention.

DESCRIPTION OF EMBODIMENTS PREFERRED AT THE TIME OF FILING FOR THISPATENT

Referring now to FIGS. 5A-5D, a screen-supporting basket 10 for avibratory separator or shale shaker has two spaced-apart side walls 12,14 and an end wall 16 between them. Typical vibrator apparatus 20 isconnectible to the basket 10. An end screen 40 is mounted in channels22, 24 on opposite sides of the end wall 16. Screen mounting apparatus46 may be any such known apparatus.

In one aspect the channels 22, 24 are open at the top so the screen 40can be introduced into the space between the channels 22, 24. Optionalremovable blocks 26, 28 on the interior of the basket hold the screen 40in place in the channels; and optional crown bars 32 on the screen 40'sexterior provide support for the screen 40. In one aspect each crown bar32 has a rubber part 34 that contacts the screen 40. Screening materialon the screen 40 (as on any screen according to the present invention)may be any suitable known screening material, including, but not limitedto one, two, three or more layers of known screening material and/ormesh, two-dimensional or three-dimensional, bonded, glued, connected orunconnected.

The screen 40 may, optionally, have a curved lower portion 42 thatcorresponds to a curved-shape assumed by screens (not shown) mounted inthe basket 10.

The screen 40 is emplaced over an opening 18 in the end wall 16.Optionally a sealing gasket 19 or other seal material or seal member isused around the opening 18.

A basket 10 (and any basket according to the present invention) may beused with any suitable known shaker or separator.

FIG. 5E shows another embodiment 10 a of a basket 10 with multiplevertical end screens 40 (as above), 40 a, and 40 b supported on lowerpart 22 a of the channel 22 and positioned beneath upper part 22 b ofthe channel 22. Alternatively, the screens may have appropriate framesor other mounting members and/or structure so that they can be bolted inplace. The screens 40 a and 40 b may be like the screen 40 with thescreening material described for the screen 40 (and like numerals inFIGS. 5A and 5E are for like items). Each screen may have similar ordifferent screening material. Two, three, four or more such screens maybe used at a basket end and/or side(s) with screens positioned within oroutside the basket.

FIG. 5F shows a screen assembly 41 according to the present inventionwhich has a frame 41 a and screening material 41 b (which may be anyscreening material layer or layers referred to herein). In one aspectthe screen assembly 41 has a frame 41 a like the frame of the frame inFIG. 6A with one, two, three, four, five or more holes (like the holes64). Alternatively, there are no holes like the holes 64 in the frame 41a (as there are in the frame in FIG. 6A) and material flows from oneside of the frame 41 a to the other through the screening material 41 b.With one or more holes (like the holes 64) present in the frame 41 asome of the material to be treated flows through screening material intothe hole(s) and some of the material to be treated (e.g., but notlimited to, drilling cuttings material) flows from one side of the frameto the other through the screening material 41 b. In one aspect thescreen 40, FIG. 5B, optionally, has hole(s) like the holes 64, FIG. 6A.Any screen assembly 40 or 41 may have a plate as in FIGS. 6B-6D and/oras in FIG. 8.

FIG. 5G illustrates a basket 10 a according to the present invention,like the basket 10, FIG. 5A, and like numerals indicate like parts. Thebasket 10 a includes a screen assembly 43 and a screen assembly 45mounted therein. It is within the scope of the present invention todelete one or two of the screen assemblies 40, 43, 45 and/or to have oneor two additional screen assemblies 40, 43 and/or 45 spaced apart in thebasket 10 a. The screen assemblies 43, 45, or either of them, may belike the screen assembly 40, the screen assembly 41 or any screenassembly according to the present invention.

As shown the screen assembly 43 is taller than the screen assembly 45.According to the present invention, this may be reversed with the screenassembly 43 in the position of the screen assembly 45 or both screenassemblies may be the same height. In certain aspects the screenassemblies are sufficiently high that little or no material to betreated flows over the top of a screen assembly. In other aspectsaccording to the present invention the screen assemblies or one of themare of such a height that a portion (e.g., but not limited to, onefourth, one half, or three-fourths) of the material first encountering ascreen assembly flows over the top thereof.

FIG. 5H shows a basket 10 b according to the present invention with fourscreen assemblies 51, 52, 54, 55 mounted therein (e.g. like the screenassemblies 40, 43, and/or 45). The screen assemblies 51, 52, 54, 55 orany of them may be as any screen assembly according to the presentinvention, including, but not limited to, the screen assemblies 40, 41,43, and/or 45 in any of their embodiments described above. In oneparticular aspect, the screen assembly 52 (and also the screenassemblies 51, 54, and 55) have a hole or holes like the holes 64, FIG.6A and material flowing to and through the hole(s) flows into an opening53 in the bottom of the basket 10 b and then into a lower receptaclebeneath the basket (and any of the other screen assemblies may be somounted above an opening like the opening 53).

Any one, two, or three of the screen assemblies in FIG. 5H may bedeleted.

Also, one or some of the screen assemblies may be mounted above anopening like the opening 53 while the remaining screen(s) are notmounted above such an opening.

Any of the screen assemblies in FIGS. 5A-5H may be used with any knownbasket or with any basket according to the present invention [providing,with respect to known baskets openings, as desired, are providedaccording to the present invention through the screen(s) in the bottomof the basket].

FIG. 6A shows part of a tubular frame 60 used as a screen support forscreening material for a screen assembly according to the presentinvention for use in a vibratory separator or shale shaker.

The frame 60 has a top member 61 and a bottom member 62.

A plurality of cross members 63 (one shown) interconnect the top andbottom members.

One, two, three, four, or more holes 64 (or a series of perforationsthrough the bottom member 62) provide for fluid flow through the bottommember 62 (shown as hollow; solid bottom members with one or more holesor perforations may be used). In one aspect the top member also has sucha hole or holes 64.

FIGS. 6B and 6C show a perforated plate 200 for supporting screeningmaterial (not shown) for a screen assembly for a vibratory separator,particularly for an end screen or side basket screen according to thepresent invention as described herein. The perforated plate 200 has aplurality of spaced-apart openings 201 or holes extending through theplate from one surface to the other. A second series of spaced-apartopenings 202 or holes extend from the topmost row of openings 201 (asviewed in FIG. 6B) to a bottom side 203 of the plate 200. Openings 202intersect openings 201 so that fluid flowing into an opening 201 canflow down (as viewed in FIG. 6B) and out from the plate 200, e.g. into areceptacle of a vibratory separator or shale shaker beneath a basket inwhich is mounted a screen assembly with such a plate.

It is within the scope of this invention for any known perforated plateor perforated member used as a support for a screen assembly which has aknown series of spaced-apart perforations, holes, openings, etc. to havea second series of perforations, openings or holes (e.g. but not limitedto like the holes 202) at any desired angle to the perforations, holesor openings, etc. through the plate (including, but not limited to at aright angle as shown in FIG. 6B) to conduct fluid through the plate asis done by the plate 200.

FIG. 6D shows a screen assembly 210 for a vibratory separator, accordingto the present invention, with a perforated plate 211 for supportingscreening material 212 on the plate 211, particularly for an end screenor side basket screen according to the present invention as describedherein. The perforated plate 211 has a plurality of spaced-apartopenings 213 or holes extending through the plate from one surface tothe other. A series of spaced-apart grooves 214 or notches extend fromone side of the plate 211 to the other and intersect the openings 213 sothat fluid flowing into an opening 213 can flow down and out from theplate 211, e.g. into a receptacle of a vibratory separator or shaleshaker beneath a basket in which is mounted a screen assembly with sucha plate. There may be multiple holes 213 under each hole 213 as viewedin FIG. 6D across the plate's surface. The screening material 212 may beany disclosed herein and/or any known in the art.

It is within the scope of this invention for any known perforated plateor perforated member used as a support for a screen assembly which has aknown series of spaced-apart perforations, holes, openings, etc. to havea second series of grooves or notches (e.g. but not limited to like thegrooves 214) at any desired angle to the perforations, holes oropenings, etc. through the plate (including, but not limited to at aright angle as shown in FIG. 6D) to conduct fluid down the plate as isdone in the plate 211.

FIGS. 7A-7F show various baskets according to the present invention.

FIG. 7A shows a basket 70 with side walls 72, end wall 73, andcross-braces 79 on which screens for treating fluid introduced into thebasket are to be mounted. End wall 73 has an end screen 74 over an endopening 71 for treating fluid introduced to the basket 70. Side screens75, 76 are mounted over side openings 77 in the side walls 72. An endbrace 78 is interconnected between side walls 72 at an exit end of thebasket 70 (opposite the other end at which fluid is introduced into thebasket).

FIG. 7B shows a basket 80 with side walls 82, end wall 83, in whichscreens for treating fluid introduced into the basket are to be mounted.End wall 83 has an end screen 84 over an end opening 81 for treatingfluid introduced to the basket 80. Side screens 85, 86 are mounted overside openings 87 in the side walls 82. An end brace 88 is interconnectedbetween side walls 82 at an exit end of the basket 80 (opposite theother end at which fluid is introduced into the basket).

FIG. 7C shows a basket 90 with side walls 92, end wall 93, andcross-braces 99 on which screens for treating fluid introduced into thebasket are to be mounted. End wall 93 has an end screen 94 over an endopening 91 for treating fluid introduced to the basket 90. Side screens95, 96 are mounted over side openings 97 in the side walls 92. An endbrace 98 is interconnected between side walls 92 at an exit end of thebasket 90 (opposite the other end at which fluid is introduced into thebasket).

FIG. 7D shows a basket 100 with side walls 102, end wall 103, andcross-braces 109. End wall 103 has an end screen 104 over an end opening101 for treating fluid introduced to the basket 100. Side screens 105,106 are mounted over side openings 107 in the side walls 102. An endbrace 108 is interconnected between side walls 102 at an exit end of thebasket 100 (opposite the other end at which fluid is introduced into thebasket). Mounting apparatus 110 (any known in the art) is used to mountscreens in the basket 100.

FIG. 7E shows a basket 120 with side walls 122, end wall 123, andcross-braces 129. End wall 123 has end screens 124, 134 over endopenings 121, 131 for treating fluid introduced to the basket 120. Sidescreens 125, 126 are mounted over side openings 127, 137 in the sidewalls 122. An end brace 128 is interconnected between side walls 122 atan exit end of the basket 120 (opposite the other end at which fluid isintroduced into the basket). Mounting apparatus 130 (any known in theart) is used to mount screens in the basket 120.

FIG. 7F shows a basket 140 with side walls 142, end wall 143, andscreens 162, 163 mounted on the basket for treating fluid introducedinto the basket. End wall 143 has an end screen 174 over an end opening141 for treating fluid introduced to the basket 140. Side screens 144,145, 146, 147, 148, 149 are mounted over side openings 154, 155, 156,157, 158, 159 in the side walls 142. An end brace 161 is interconnectedbetween side walls 142 at an exit end 182 of the basket 140 (oppositethe other end at which fluid is introduced into the basket). A solidsheet or plate 180 is mounted in the basket at the fluid introductionend 184 opposite the solids exit end 182. The solid sheet or plate 180performs no fluid treatment function of separating components of a fluidintroduced into the basket 140. The end screen 174 and side screensand/or side screen portions adjacent the solid sheet or plate 180 doperform a fluid component separation function. It is within the scope ofthis invention for the solid sheet or plate to be sized so that itunderlies a pond or pool (e.g. as shown in FIG. 4, item 9). It is alsowithin the scope of this invention for the solid sheet or plate toextend from the end wall 143 toward the exit end 182 six inches, onefoot, eighteen inches, two feet, thirty inches, three feet, forty twoinches, four feet, or any desired amount. Alternatively, the sheet orplate 180 may have a series of slits, slots, holes, openings and/orperforations therethrough so that the sheet or plate 180 does perform afluid component separation function; and, in one such embodiment, theslits, slots, holes, openings and/or perforations (collectively referredto as “holes”) are of a size like that of a finest screen mesh on top ofa screen or screens used for the screens 162, 163. Any screen or screenassembly may be used in the basket 140. Any sheet or plate 180 may beused in any known basket or any basket according to the presentinvention.

FIG. 8 shows a plate 180 with a plurality of perforations 185therethrough.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a screen mounting basket for a vibratoryseparator for separating components of material introduced into thebasket, the vibratory separator including a collection receptaclebeneath the basket, the basket with two opposed spaced-apart side wallshaving first ends and second ends, the first ends spaced-apart by an endwall connected to each of the side walls, a basket bottom openingbetween the two spaced-apart side walls, basket bottom screeningapparatus at the basket bottom opening, at least one basket aperture notthrough the basket bottom, at least one aperture screen over the atleast one basket aperture, and the at least one aperture screen and thebottom screening apparatus for separating a component material from thematerial introduced into the basket, material flowing through the atleast one aperture screen not flowing through the bottom screeningapparatus, the separated component material flowing into the collectionreceptacle. Such a method may include one or some of the following, inany possible combination: wherein the basket aperture is through the endwall; wherein the basket aperture is through one of the two spaced-apartside walls; wherein the at least one aperture screen has a support witha plurality of openings therethrough suitable for the flow of fluidtherethrough, the fluid from the material introduced into the basket,and the at least one aperture screen having one or a plurality of fluidconducting channels therein at an angle to the plurality of openings sothat fluid flowing into one of the plurality of openings may then flowinto the one or one of the plurality of fluid conducting channels andout from the support into the receptacle; wherein the support is a frameand the plurality of fluid conducting channels is a plurality of holesin part of the frame; wherein the support is a perforated plate, theplurality of openings is a plurality of openings through the perforatedplate, and the plurality of fluid conducting channels is a plurality ofholes through the perforated plate; and/or wherein the materialintroduced to the basket is drilling fluid with undesirable materialtherein and the separated component is drilling fluid.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a screen mounting basket for a vibratoryseparator for separating components of material introduced into thebasket, the vibratory separator including a collection receptaclebeneath the basket, the basket with two opposed spaced-apart side wallshaving first ends and second ends, the first ends spaced-apart by an endwall connected to each of the side walls, a basket bottom openingbetween the two spaced-apart side walls, at least one end openingthrough the end wall, at least one end screen over the at least one endopening, at least one basket screen over the basket bottom opening, andthe at least one end screen and the at least one basket screen forseparating a component from the material, material flowing through theat least one aperture screen not flowing through the bottom screeningapparatus, the separated component flowing into the collectionreceptacle. Such a method may include one or some of the following, inany possible combination: wherein the basket has at least one sideopening in one of the two spaced-apart sides and at least one sidebasket screen is mounted over the at least one side opening forseparating a component from the material; wherein the at least onebasket screen is a two-dimensional screen; wherein the at least onebasket screen is a three-dimensional screen; wherein the at least oneend screen is within the basket; wherein the at least one end screen isreleasably secured to the basket; wherein the at least one side basketscreen is within the basket; wherein the at least one side basket screenis releasably secured to the basket; wherein the at least one end screenis a plurality of end screens adjacent each other end-to-end over the atleast one end opening; wherein the at least one end screen is aplurality of end screens positioned vertically adjacent and parallel toeach other over the at least one end opening; wherein the at least oneside basket screen is a plurality of side basket screens adjacent eachother end-to-end over the at least one side basket opening; wherein theat least side basket screen is a plurality of side basket screenspositioned vertically adjacent and parallel to each other over the atleast one side basket opening; wherein the at least one end screenopening is plurality of adjacent end openings and the at least one endscreen is a plurality of end screens each over an opening of theplurality of end openings; wherein the at least one side basket openingis plurality of side basket openings and the at least one side basketscreen is a plurality of side basket screens each over an opening of theplurality of side basket openings; wherein the material introduced tothe basket is drilling fluid with undesirable material therein and theseparated component is drilling fluid; wherein the at least one endscreen has a support with a plurality of openings therethrough suitablefor the flow of fluid therethrough, the fluid from the materialintroduced into the basket, and the at least one end screen having oneor a plurality of fluid conducting channels therein at an angle to theplurality of openings so that fluid flowing into one of the plurality ofopenings may then flow into one of the one or plurality of fluidconducting channels and out from the support; wherein the support is aframe and the plurality of fluid conducting channels is a plurality ofholes in part of the frame; and/or wherein the support is a perforatedplate, the plurality of openings is a plurality of openings through theperforated plate, and the plurality of fluid conducting channels is aplurality of holes through the perforated plate.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a screen apparatus for a vibratoryseparator, the vibratory separator having a basket, the vibratoryseparator for separating components of material introduced into thebasket, the vibratory separator including a collection receptaclebeneath the basket, the screen apparatus with screening material, asupport, the screening material on the support, the support having aplurality of openings therethrough suitable for the flow of fluidtherethrough, the fluid from the material introduced into the basket,the support having one or a plurality of fluid conducting channelstherein at an angle to the plurality of openings so that fluid flowinginto one of the plurality of openings may then flow into one of theplurality of fluid conducting channels and out from the support into thereceptacle. Such a method may include one or some of the following, inany possible combination: screen apparatus wherein the materialintroduced into the basket is drilling fluid with undesirable materialtherein and the screen apparatus is for separating drilling fluid fromthe material; wherein the plurality of fluid conducting channelscomprises a plurality of grooves in a surface of the support, eachgroove intersecting openings of the plurality of openings in thesupport; wherein the support is a frame and the plurality of fluidconducting channels is a plurality of holes in part of the frame; and/orwherein the support is a perforated plate, the plurality of openings isa plurality of openings through the perforated plate, and the pluralityof fluid conducting channels is a plurality of holes through theperforated plate.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a screen mounting basket for a vibratoryseparator for separating components of material introduced into thebasket, the vibratory separator including a collection receptaclebeneath the basket, the basket with two opposed spaced-apart side wallshaving first ends and second ends, the first ends spaced-apart by an endwall connected to each of the side walls, a basket bottom openingbetween the two spaced-apart side walls, at least one side basketopening through one of the two spaced-apart side walls, at least oneside basket screen over the at least one side basket opening, at leastone basket screen over the basket bottom opening, and at least one sidebasket screen over the at least one side basket opening, at least onebasket screen over the basket bottom opening, and the at least one sidebasket screen and the at least one basket screen for separating acomponent from the material, component material separated by the atleast one side basket screen not flowing through the at least one basketscreen, the separated component material flowing into the collectionreceptacle.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a vibratory separator system for separatingcomponents from a liquid-solid mixture fed to the vibratory separatorsystem, the vibratory separator system with a frame, a screen mountingbasket on the frame, vibrating apparatus connected to the screenmounting basket for vibrating the screen mounting basket, the screenmounting basket with two opposed spaced-apart side walls having firstends and second ends, the first ends spaced-apart by an end wallconnected to each of the side walls, a basket bottom opening between thetwo spaced-apart side walls, basket bottom screening apparatus at thebasket bottom opening, at least one basket aperture not through thebasket bottom, at least one aperture screen over the at least one basketaperture, and the at least one aperture screen and the bottom screeningapparatus for separating a component material from the materialintroduced into the basket, material flowing through the at least oneaperture screen not flowing through the bottom screening apparatus, theseparated component material flowing into the collection receptacle; andsuch a vibratory separator system wherein the liquid-solid mixture isdrilling fluid with undesirable material therein and the componentseparated by the at least one aperture screen is drilling fluid.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a method for separating components of amaterial with a vibratory separator, the vibratory separator having ascreen mounting basket into which the material is introduced, thevibratory separator including a collection receptacle beneath thebasket, the basket with two opposed spaced-apart side walls having firstends and second ends, the first ends spaced-apart by an end wallconnected to each of the side walls, a basket bottom opening between thetwo spaced-apart side walls, basket bottom screening apparatus at thebasket bottom opening, at least one basket aperture not through thebasket bottom opening, at least one aperture screen over the at leastone basket aperture, and the at least one aperture screen and the bottomscreening apparatus for separating a component material from thematerial introduced into the basket, the separated component materialflowing into the collection receptacle, the method including introducingthe material into the basket, separating a component of the materialwith the basket bottom screening apparatus and with the at least oneaperture screen, component material separated by the at least oneaperture screen not flowing through the basket bottom screeningapparatus and the thus separated component material flowing into thereceptacle.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a method for separating components of amaterial with a vibratory separator, the vibratory separator having ascreen mounting basket into which the material is introduced, thevibratory separator including a collection receptacle beneath thebasket, the basket with two opposed spaced-apart side walls having firstends and second ends, the first ends spaced-apart by an end wallconnected to each of the side walls, a basket bottom opening between thetwo spaced-apart side walls, at least one end opening through the endwall, at least one end screen over the at least one end opening, atleast one basket screen over the basket bottom opening, and the at leastone end screen and the at least one basket screen for separating acomponent from the material, the separated component flowing into thecollection receptacle, the method including introducing the materialinto the basket, separating a component of the material with the atleast one basket screen and with the at least one end screen, componentmaterial flowing through the at least one end screen not flowing throughthe at least one basket screen and the thus separated component materialflowing into the receptacle.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a method for reducing the weight ofmaterial on the bottom screening apparatus of a vibratory separator, thevibratory separator having a screen mounting basket into which thematerial is introduced, the vibratory separator including a collectionreceptacle beneath the basket, the basket with a plurality ofinterconnected walls, a basket bottom opening between the walls, basketbottom screening apparatus at the basket bottom opening, at least onebasket aperture through one of the walls and not through the basketbottom, at least one aperture screen over the at least one basketaperture, and the at least one aperture screen and the bottom screeningapparatus for separating a component material from the materialintroduced into the basket, the separated component material flowinginto the collection receptacle, the method including introducing thematerial into the basket, flowing part of the material through the atleast one aperture screen, said part flowing into the receptacle withoutpassing through the bottom screening apparatus.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a screen mounting basket for a vibratoryseparator or shale shaker for separating components of material (e.g.drilling cuttings material) introduced into the basket, the vibratoryseparator or shaker including a collection receptacle beneath thebasket, the basket including: two opposed spaced-apart side walls havingfirst ends and second ends, the first ends spaced-apart by spaced-apartend walls connected to each of the side walls; a basket bottom betweenthe two spaced-apart side walls; at least one screen assembly or aplurality of such assemblies positioned vertically in the basket forintercepting material introduced into the basket and for screening saidmaterial; and the screen assembly or screen assemblies extending fromone side wall of the basket to the other.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a screen mounting basket for a vibratoryseparator or shale shaker for separating components of material (e.g.drilling cuttings material) introduced into the basket, the vibratoryseparator or shaker including a collection receptacle beneath thebasket, the basket including: two opposed spaced-apart side walls havingfirst ends and second ends, the first ends spaced-apart by spaced-apartend walls connected to each of the side walls; a basket bottom betweenthe two spaced-apart side walls; at least one screen assembly or screenassemblies positioned vertically in the basket for intercepting materialintroduced into the basket and for screening said material; the screenassembly or assemblies extending from one side wall of the basket to theother; a or a plurality of basket bottom openings; the at least onescreen assembly or each assembly positioned over a basket bottomopening; and each screen assembly having at least one fluid conductinghole so that a portion of the material introduced into the basket isflowable into the or each screen assembly and through the at least onefluid conducting hole into the basket bottom opening and thence into thecollection receptacle.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a vibratory separator system for separatingcomponents from a liquid-solid mixture fed to the vibratory separatorsystem, the vibratory separator system including a base, a screenmounting basket on the base, vibrating apparatus connected to the screenmounting basket for vibrating the screen mounting basket, and a screenmounting basket according to the present invention.

In conclusion, therefore, it is seen that the present invention and theembodiments disclosed herein and those covered by the appended claimsare well adapted to carry out the objectives and obtain the ends setforth. Certain changes can be made in the subject matter described,shown and claimed without departing from the spirit and the scope ofthis invention. It is realized that changes are possible within thescope of this invention and it is further intended that each element orstep recited in any of the following claims is to be understood asreferring to all equivalent elements or steps. The following claims areintended to cover the invention as broadly as legally possible inwhatever form its principles may be utilized.

1. A screen mounting basket for a vibratory separator for separatingcomponents of material introduced into the basket, the vibratoryseparator including a collection receptacle beneath the basket, thebasket comprising two opposed spaced-apart side walls having first endsand second ends, the first ends spaced-apart by spaced-apart end wallsconnected to each of the side walls, a basket bottom between the twospaced-apart side walls, at least one screen assembly positionedvertically in the basket for intercepting material introduced into thebasket and for screening said material, and the at least one screenassembly extending from one side wall of the basket to the other.
 2. Thescreen mounting basket of claim 1 wherein the at least one screenassembly is a plurality of spaced-apart screen assemblies.
 3. The screenmounting basket of claim 1 further comprising a basket bottom opening,the at least one screen assembly positioned over the basket bottomopening, the at least one screen assembly having at least one fluidconducting hole so that a portion of the material introduced into thebasket is flowable into the screen assembly and through the at least onefluid conducting hole into the basket bottom opening and thence into thecollection receptacle.
 4. The screen mounting basket of claim 1 furthercomprising a basket bottom opening between the two spaced-apart sidewalls, at least one end opening through the end wall, at least one endscreen over the at least one end opening, at least one basket screenover the basket bottom opening, and the at least one end screen and theat least one basket screen for separating a component from the material.5. The screen mounting basket of claim 4 wherein the basket has at leastone side opening in one of the two spaced-apart sides and at least oneside basket screen is mounted over the at least one side opening forseparating a component from the material.
 6. The screen mounting basketof claim 4 wherein the at least one basket screen is a two-dimensionalscreen.
 7. The screen mounting basket of claim 4 wherein the at leastone basket screen is a three-dimensional screen.
 8. The screen mountingbasket of claim 1 wherein the material introduced to the basket isdrilling fluid with undesirable material therein and a separatedcomponent is drilling fluid.
 9. The screen mounting basket of claim 1further comprising the at least one screen assembly including a supportand screening material on the support.
 10. The screen mounting basket ofclaim 9 wherein the support is a frame.
 11. The screen mounting basketof claim 10 wherein the frame has a plurality of fluid conductingchannels therethrough.
 12. The screen mounting basket of claim 7 whereinthe support is a perforated plate with a plurality of openingstherethrough and a plurality of fluid conducting channels through theperforated plate.
 13. The screen mounting basket of claim 1 furthercomprising at least one end opening through the end wall, at least oneend screen over the at least one end opening, and the at least one endscreen for separating a component from the material.
 14. A screenmounting basket for a vibratory separator for separating components ofmaterial introduced into the basket, the vibratory separator including acollection receptacle beneath the basket, the basket comprising twoopposed spaced-apart side walls having first ends and second ends, thefirst ends spaced-apart by spaced-apart end walls connected to each ofthe side walls, a basket bottom between the two spaced-apart side walls,at least one screen assembly positioned vertically in the basket forintercepting material introduced into the basket and for screening saidmaterial, the at least one screen assembly extending from one side wallof the basket to the other, wherein the at least one screen assembly isa plurality of spaced-apart screen assemblies, a basket bottom opening,the at least one screen assembly positioned over the basket bottomopening, the at least one screen assembly having at least one fluidconducting hole so that a portion of the material introduced into thebasket is flowable into the screen assembly and through the at least onefluid conducting hole into the basket bottom opening and thence into thecollection receptacle, and wherein the material introduced to the basketis drilling fluid with undesirable material therein and a separatedcomponent is drilling fluid.
 15. A vibratory separator system forseparating components from a liquid-solid mixture fed to the vibratoryseparator system, the vibratory separator system comprising a base, ascreen mounting basket on the base, vibrating apparatus connected to thescreen mounting basket for vibrating the screen mounting basket, thescreen mounting basket comprising two opposed spaced-apart side wallshaving first ends and second ends, the first ends spaced-apart byspaced-apart end walls connected to each of the side walls, a basketbottom between the two spaced-apart side walls, at least one screenassembly positioned vertically in the basket for intercepting materialintroduced into the basket and for screening said material, and the atleast one screen assembly extending from one side wall of the basket tothe other.